Note: Descriptions are shown in the official language in which they were submitted.
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Title: WOOD ARTICLE AND METHOD OF MANUFACTURE
FIELD OF THE INVENTION
This invention relates generally to an article of wood
manufactured from a plurality of individual wood members. In one
embodiment, the invention relates in particular to composite
structural wood members, such as building studs and the like, and
their method of manufacture.
BACKGROUND OF THE PRESENT INVENTION
Dimensional lumber used in construction, such as
building studs and other structural building members, are generally
prepared by cutting a unitary piece of lumber to the desired size. For
example, a typical 2 x 4 building stud is prepared by cutting a larger
piece of lumber to the requisite size.
In operation, logs may be cut at a saw mill to produce
lumber of various sizes. The number of pieces of lumber of any
particular size which may be produced from a log is limited by the size
of the log. For any given size log, a larger number of smaller pieces of
lumber may be produced. A log may be cut so as to maximize the
number of usable pieces of lumber from a log. Accordingly, for
example, the number of pieces of lumber which are suitable for
manufacturing 2 x 4's from any particular log is limited.
In the industry, composite wood members may be made
in a variety of different ways. These are typically made by gluing wood
pieces of differing sizes of together. For example, plywood, oriented
strand board and particle board are prepared by adhering pieces of
wood of varying sizes together. See also United States Patent No.
4,624,295 to Howland which discloses a method of producing wood
panels by finger joining wood members together.
Methods have also been developed to produce composite
wood members from two members, one of which is a high grade wood
and the other of which is a low grade wood. See for example United
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States Patent Nos. 647,626 (Gilmour), 647,627 (Gilmour) and 1,409,410
(Rockwell). These processes are directed at producing a composite
wood product which has a good surface appearance by using lesser
quality wood.
5 SUMMARY OF THE PRESENT INVENTION
In accordance with the instant invention there is provided
a wood member comprising first and second opposed members made
of wood and secured together, each of the first and second members
having spaced sides and a surface extending between the sides, the
10 surfaces including a first portion contoured to define a contact surface
which extends in more than one plane, the first portions defining a
space therebetween for receiving an adhesive for securing the first and
second members together; a second portion contoured to restrict the
flow of the adhesive to a position outward from the sides when the
15 first and second members are brought into engagement; and, opposed
engagement members configured to lockingly engage without
substantial deformation of the engagement members and secure the
first and second members together as the adhesive dries.
In accordance with a further embodiment of this
20 invention there is provided a wood member adapted to be secured to
an opposed second such member, the wood member having spaced
sides and a surface extending between the sides, the surface including a
first portion contoured to define a contact surface which extends in
more than one plane and, when the first member is combined with a
25 second such member, the first portions of the first and second
members define a space therebetween for receiving an adhesive for
securing the first and second members together; a second portion
contoured to restrict the flow of the adhesive to a position outward
from the sides when the first member is secured to a second such
30 member; and, engagement means to engage with engagement means
of a second such member without substantial deformation of the
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engagement means and secure the first and second members together
as the adhesive dries when the first and second members are brought
into engagement.
In accordance with a further embodiment of this
5 invention there is provided a wood member comprising first and
second opposed longitudinally extending wood members secured
together by securing means, each of the first and second members
having spaced longitudinally extending sides and a contact surface
extending between the sides, the securing means comprising
10 longitudinally extending complimentary tongues and grooves
provided on a portion of the contact surfaces, the tongues and grooves
dimension to define a first channel therebetween; locking means
comprising opposed engagement members provided on a portion of
the contact surfaces adjacent each of the sides wherein, prior to the first
15 and second members being secured together, each of the engagement
members has an abutment member and a recess member, the
engagement members dimensioned to define a second channel
therebetween; and adhesive provided in the first and second channels.
In accordance with a further embodiment of this
20 invention there is provided a method of manufacturing a wood
member from a plurality of individual members, each of the
individual members having spaced sides, the method comprising the
steps of cutting lengthwise in a surface of each of the individual
members a complimentary contact surface which extends in more
25 than one plane, the contact surfaces being configured such that, when
the individual members are combined together, the contact surfaces
define a space therebetween for receiving an adhesive; cutting
lengthwise in each of the surfaces engagement means such that, when
the individual members are combined together, the engagement
30 means engage without substantial deformation of the engagement
means; applying an adhesive to the contact surface and the
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engagement means of at least one of the individual members; and,
aligning the contact surface and the engagement means of one of the
individual members with a complementary contact surface and
engagement means of a second of the individual members and
causing the engagement means to interengage to form the wood
member.
One advantage of the instant invention is that the wood
member may be used as a structural building member. For example,
the wood member may be building studs such as a 2x4 or other
structural elements used in construction (e.g. in the framing of the
sides or roof of a house or other structure).
In a preferred embodiment of this invention, the contact
surface comprises a plurality of fingers and grooves. More preferably,
the fingers may be in the shape of truncated triangular members and
the grooves are complimentarily shaped to receive the fingers in a
non-interference fit. This provides an extended contact surface
between the first and second members. When manufactured, the
extended contact area between the opposed surfaces assists the wood
member to resist warping.
In the further preferred embodiment, the engagement
members are positioned adjacent each of the sides of the wood
member. The engagement members secure the wood together while
the adhesive is drying. The first and second opposed members may be
secured together by applying a layer of adhesive between the two layers
and then pressing the first and second members together, such as in a
- press or the like. Once the engagement members having lockingly
engaged, the wood member may be removed from the press and
moved to a storage area where the adhesive may dry. The engagement
members advantageously maintain contact between the interior faces
of the opposed members while the adhesive dries thus reducing the
required press time.
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Further, by positioning the engagement members adjacent
each of the sides, the flow of adhesive out of the sides of the wood
member during the pressing step is reduced thus preventing the
adhesive from adhering to the press or to the sides of the wood.
A further advantage of the instant invention is that the
wood member may by manufactured from smaller elements. For
example, a 2x4 may be manufactured from two 1x5's. As the cost of two
1x5's is generally less than the cost a 2x4 of similar grade, a 2x4
manufactured by the method of the instant invention may be prepared
at a lower cost than a standard 2x4.
DESCRIPTION OF THE DRAWING FIGURES
These and other advantages of the instant invention will
be more fully and completely understood in accordance with the
following description of a preferred embodiment of the invention in
which:
Figure 1 is a perspective view of a wood member
according to the instant invention; and,
Figure 2 is a perspective view of one of the members
forming the wood member shown in Figure 1.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to Figure 1, wood member 10 may consist of the
first member 12 and the second member 14. Wood member 10 has an
upper surface 16. Each member 12 and 14 has longitudinally extending
sides 18 which extends between end 20 and a distal end (not shown).
Referring to Figure 2, each member 12 and 14 has a surface 22 along
which first and second members 12 and 14 matingly engage to form
wood member 10.
Wood member 10 may be used for various ways.
Preferably, wood member 10 is adapted for use as a structural member
and accordingly may comprise a composite piece of dimensional
lumber. For example, wood member 10 may used as a structural
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member during the construction of buildings and may be used in
framing the sides and roofs of such buildings. Wood member 10 may
accordingly be a 2x3, a 2x4, a 2x6 or other size.
First and second members 12 and 14 may be prepared from
5 wood of any particular size. They may be manufactured from a unitary
piece of lumber that is approximately the size of the desired
dimensions of member 12 or 14. Preferably, they are manufactured
from members which are approximately half the size of the desired
dimensions of wood member 10. For example, if wood member 10 is a
102x4 stud, then first and second members 12 and 14 may be prepared
from lx5's. The grade of wood used to produce first and second
members 12 and 14 is selected based upon the desired grade of wood
member 10. Preferably wood members 12 and 14 are prepared from
kiln dried lumber.
15The exterior surfaces of wood member 10, such as upper
surface 16, may have any desired finish. For example, if wood member
10 is to be used as a building stud, then it may have a standard finish to
meet North American tolerance requirements. Alternately, the outer
surface of wood member 16 may be dimensioned and finished to meet
20 the tolerances of any particular building code or surface finish which
may be required.
Surface 22 has a first portion 24 and engagement members
26. First portion 24 defines an extended contact surface. Surface 24 is
configured so as to provided a surface to bond members 12 and 14
25 together and to resist warping of wood member 10. Accordingly, this
surface preferably extends in more than one plane. As shown in Figure
2, first portion 24 may comprise a plurality of tongues 28 and grooves
30. Preferably, tongues 28 are truncated triangular members.
Accordingly, for example, a tongue 28 of second member 14 will be
30 received in a complementary groove 30 of first member 12. These
tongues and grooves define an extended contact surface between first
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and second members 12 and 14. Accordingly, they provide an extended
surface along which members 12 and 14 may be glued together.
Further, they assist in locking members 12 and 14 together to resist
shearing stresses and other forces which may tend to try and separate
wood members 12 and 14. Further, they assist wood member 10 to
resist warping.
First portion 24 is dimension so that when first and
second members 12 and 14 are assembled, first portions 24 define a
channel 32. Channel 32 is sized to receive an effective amount of
adhesive to bond first and second members 12 and 14 together.
Accordingly, for example, tongues 28 may be cut so as to be slightly
smaller than grooves 30 so as to produce channel 32. Channel 32 may
be dimension to have a thickness in the order of a few thousands of an
inch.
A preferred layout of surface 22 is shown in Figure 2.
According to this layout, first portion 24 is centrally located on surface
22 and engagement members 26 are provided adjacent each side 18. If
an member 10 having a larger transverse dimension is being
produced, additional engagement members may be provided at
interior positions with respect to sides 18 and first portions 24 may
extend between the engagement members.
During the manufacturing process, adhesive is applied to
at least one surface 22. When first and second members 12 and 14 are
pressed together some of the adhesive may have a tendency to flow
outwards of wood member 10. For example, the adhesive may flow
transversely towards sides 18. Preferably, engagement members 26 are
provided adjacent sides 18 to restrict the flow of adhesive transversely
out of wood member 10. If too much adhesive exits at sides 18, this
may damage the machinery used in the manufacturing operation.
Further, depending upon the intended use of wood member 10,
excessive glue build up on sides 18 may be undesirable. Accordingly, if
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engagement members 26 are not provided adjacent sides 18, but at an
interior position, then surface 22 preferably includes a second portion
which is contoured to restrict the flow of adhesive transversely out of
wood member 10. It will be appreciated that the engagement members,
when positioned adjacent sides 18, define such a second portion.
Engagement members 26 are configured and positioned to
lockingly engage first and second members 12 and 14 together and to
maintain first and second members 12 and 14 together as the adhesive
dries without substantial deformation of engagement members 26. As
will be appreciated, engagement members 36 preferably define a
channel, which may be smaller than channel 32, for receiving an
adhesive. Accordingly, once the adhesive dries, engagement members
36 are bonded together.
In the preferred embodiment shown in Figure 2,
engagement member 26 comprises abutment member 36 and recess
member 38.
Referring to Figure 1, it can be seen that abutment
member 36 of first member 12 is received in recess member 38 of
second member 14. Similarly, abutment member 36 of second member
14 is received in recess member 38 of first member 12. Referring to
Figure 1, line A is a line extending parallel to side 18 positioned at the
distal edge of abutment member 36 of second member 14. As shown in
Figure 1, recess member 38 of second member 14 defines a cavity
transverse of line A and beneath abutment member 36 of second
member 14. This cavity is adapted to receive an abutment member.
Abutment member 36 of first member 12 extends transversely past line
A towards side 18 so as to received beneath abutment member 36 in
recess member 38. Similarly, abutment member 36 of second member
14 is received in recess member 38 of first member 12 above abutment
36 of first member 12. A similar configuration is shown on the other
side of wood member 10. Accordingly, engagement members 26 create
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an inlel~rel.ce fit which lockingly engages first and second members
12 and 14.
As discussed below, a preferred method of manufacturing
wood member 10 is by positioning members 12 and 14 in an overlying
5 relationship and then compressing the members thereby forcing
engagement members 26 to interengage. In order to assist this
operation, engagement members 26 preferably includes cam means to
assist engagement members 26 to interengage. Accordingly, as shown
in Figure 2, abutment member 36 of second member 14 may have a
10 curved upper surface 40 which defines a cam surface along which
abutment member 36 of first member 12 may travel as first and second
members 12 and 14 are pressed together. Similarly, abutment member
36 of first member 12 may also have a cam means. Preferably,
abutment member 36 and recessed member 38 define an S shaped
15 profile as may best be seen in Figure 1.
As will appreciated, abutment members 36 do not
significantly deform during this operation. If abutment member 36
were to significantly deform, then abutment members 36 would not
interact with recess members 38 to lockingly engage first and second
20 members 12 and 14.
Referring to Figure 2 line B, is a line extending across the
upper surfaces of tongues 28 parallel to the bottom surface of second
member 14. Preferably, surface 34 is inclined at an angle oc with respect
to line B. Preferably, angle oc varies from about 5 to about 10~ and,
25 more pre~Lably, angle oc is about 7~.
The following is a description of a preferred method of
manufacturing wood member 10.
In order to prepare wood member 10, first and second
members 12 and 14 must first be prepared. First and second members
30 12 and 14 may be prepared by cutting the appropriately dimension
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blocks from larger pieces of lumber. The dimensions of first and
second members 12 and 14, and accordingly the dimension of the
lumber from which they are cut, are based upon the preselected
dimensions of wood member 10. Once the dimensions of wood
5 member 10 are determined, lumber is selected for preparing first and
second members 12 and 14. Preferably, first and second members 12
and 14 are sized so that they have approximately the same thickness.
Accordingly, the interface of first and second members 12 and 14 is
positioned adjacent the centre of the thickness of wood member 10.
Preferably, the surfaces of members 12 and 14 which will
define the outer surfaces of wood member 10 (e.g. sides 18 and surface
16) are planed to within the desired tolerances which wood member 10
must meet.
Subsequently, the desired profile of surface 22 is cut into a
15 surface of wood members 12 and 14. This profile may be cut by any
means known in the art. Once cut, members 12 and 14 may then be
stored for later use or may proceed immediately to manufacture wood
member 10.
When it is desired to manufacture wood member 10,
20 second member 14 may be provided. A layer of adhesive may then be
applied to surface 22 thereof. If desired, a layer of adhesive may also be
applied to surface 22 of first member 12. A sufficient amount of
adhesive to bond members 12 and 14 together is applied. The layer of
adhesive is preferably applied at least substantially across surface 22
25 and, more preferably, continuously across surface 22. The adhesive
may be any wood glue.
First member 12 is then positioned so that surface 22 of
first member 12 is opposed to surface 22 of second member 14 and
aligned so that first portions 24 are complimentary to each other and
30 engagement means 26 are aligned to interlock when first and second
members 12 and 14 are brought together. Once first and second
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members 12 and 14 are aligned, they are pressed together, such as by
passing them through a press with sufficient force such that
engagement members 26 interengage.
Once engagement members 26 interengage, wood member
5 10 may be removed from the press and taken to an area where the
adhesive may cure. Accordingly, one advantage of the instant
invention is that the required press time for manufacturing wood
member 10 may be minimized. Due to the provision of engagement
members 26, first and second members 12 and 14 do not need to
10 remain in the press until the adhesive dries.
As will be observed from Figure 1, first and second
members 12 and 14 may be cut with the same profile. Accordingly, in
the manufacturing operation, member 12 and 14 may be selected from
any of those members which are cut in the preliminary stage.
15 Accordingly, a further advantage of the instant invention is that only a
single cutting line need to be set up and only a single series of
members needs to be stored. When it desired to manufacture wood
member 10, two pre-cut members are taken. Once the adhesive is
applied to surface 22 of one of the members, the other member may be
20 inverted (creating a mirror profile) so as to form wood member 10.
It will be appreciated by those skilled in the art that other
modification may be made to the wood member and the method
disclosed herein and all are considered within the scope of this
invention. For example, by modifying the method of the instant
25 invention, a wood member comprising a plurality of members 12 and
14 may be prepared. For example, surface 22 may be cut in surface 16 of
first member 12. A complimentary shaped second member 14 may
then be secured to upper surface 16 of first member 12.
